Universal power operator

ABSTRACT

A universal power operator for shifting a movable barrier, such as a gate, and a circuit control system for operation thereof, is shown that allows the operator to be assembled for both a left-hinged or right-hinged movable barrier. The universal power operator includes generally an actuator arm, a housing assembly, a gear assembly, and a modular drive motor. The housing assembly contains generally symmetrical portions allowing the user to interchangeably assemble the motor in one of two positions for use with a left-hinged or right-hinged movable barrier.

RELATED APPLICATION

[0001] This application claims the benefit of U.S. ProvisionalApplication No. 60/361,120 filed Mar. 1, 2002.

FIELD OF THE INVENTION

[0002] The invention relates generally to a universal power operator,and more particularly, to a universal power operator for shifting amovable barrier.

BACKGROUND OF THE INVENTION

[0003] Operator assemblies, such as gate operators, are typically usedfor the opening and closing of movable barriers, such as gates forselectively permitting access to a driveway or a walkway. These gateoperators may use a system of linkage arms to pivot a hinged gate aboutits hinges and move the gate between open and closed positions.

[0004] Gate operators typically have a motor with an output shaft offsetfrom the linkage or operating arms connected to the gates. However,offsetting the motor may require two different models of gate operatorsto be made, one for operating gates hinged on their left sides andanother for operating gates hinged on their right sides. Two models arerequired because many gate operators typically should be flush with butnot touching the gate, and an offset motor protrudes to one side or theother of a gate operator. Accordingly, one type of gate operator may betoo bulky to be used on one side and/or will not be able to be used witha particular gate configuration due to interference with the offsetmotor.

[0005] Providing two different models of gate operators, each designedfor a specific hinge orientation of the gate, is disadvantageous in thatit may increase the complexity and cost of producing the two differentgate operators. Furthermore, having gate operators configured for solelyright or left hand hinged gates limits the versatility of the operators.Thus, a universal power operator that can be used with different gateconfigurations would be desirable.

SUMMARY OF THE INVENTION

[0006] In accordance with the invention, a power operator for shifting amovable barrier, such as a gate, and a circuit control system foroperation thereof, is provided that allows the operator to be assembledfor both a left-hinged or right-hinged movable barrier to provide a moreuniversal use thereof. Providing a standardized operator assembly thatcan be assembled by the end user for use with either type of movablebarrier increases the versatility of the operator assembly. Iteliminates the need for the end user to buy two different models ofoperators. Further, it reduces manufacturing costs by eliminating theneed for additional tooling as well as eliminating additional costsassociated with having both model configurations in stock.

[0007] The universal power operator herein preferably includes arelatively small number of parts for ease of assembly and to reducecosts. The components of the operator are easily integrated with eachother during assembly. The operator may be assembled by end users from akit, may be installed by professional installers, or may be stock itemsthat the manufacturer can employ in production.

[0008] The universal power operator includes a modular motor that can bemounted in either of two positions, for example, to a substantiallysymmetrical housing assembly and a gear assembly that is accessible tothe motor from either side. The motor includes an output shaft, and theuser may assemble the motor by mounting the output shaft to the gearassembly. The motor may be positioned in a first position relative tothe housing assembly, allowing the operator to open and close aleft-hinged gate, and may be removed and repositioned in a secondposition, allowing the operator to open and close a right-hinged gate.This interchangeable assembly allows the user to select theconfiguration or position of the motor so as to provide the requiredclearance for a particular configuration of movable barrier, allowingthe universal power operator to be used with either type of movablebarrier. In addition, it preferably provides a pleasing symmetricalappearance to passersby.

[0009] The universal power operator further includes an actuator drivenby the motor for shifting the movable barrier. The motor may have apredetermined power rating and may drive the actuator with apredetermined force. The actuator has an actuator arm that is pivotallyconnected to a movable barrier to push and pull the movable barrierbetween open and closed positions.

[0010] In addition, the actuator has a drive shaft that can beoperatively interconnected with the output shaft of the motor. The motordrives the actuator through the use of an intermediate gear assemblybetween the drive shaft of the actuator and the motor output shaft. Theintermediate gear assembly transmits rotation from the motor outputshaft to the actuator drive shaft to shift the actuator arm betweenretracted and extended positions. When fully retracted, the actuator armmay be disposed within the housing assembly along the housing axis. Thearm may also be axially extended out from the housing for shifting ofthe movable barrier.

[0011] The housing assembly has portions that are generallysymmetrically arranged on either side of the housing axis. Theseportions form substantially symmetrical spaces in which the motor outputshaft can be received to drive the gear assembly, and in turn drive theactuator arm. These substantially symmetrical spaces allow the motor tobe repositioned in one of two positions relative to the housing assemblybased on whether the movable barrier is a left-hinged or right-hingedoperating gate. This symmetry allows assembly of the motor to eitherlateral side of the housing axis.

[0012] The drive shaft may comprise a threaded screw coaxially alignedwith the arm, the threaded screw having a threaded region adapted forengagement with an internal thread or nut provided on the second end ofthe arm. The threaded screw may be arranged for rotation by the gearassembly, such that rotation of the motor output shaft will causerotation of the threaded screw. Rotation of the threaded screw may thencause the nut and thus the arm to be advanced or retracted relativethereto, depending upon the direction of rotation of the motor outputshaft.

[0013] As stated above, the universal power operator includes a modularmotor that can be mounted in either of two positions. The presentinvention further includes a circuit control system for changing theoperation of the motor depending on how the motor is mounted. Forexample, when the motor is mounted in one position corresponding to aleft-hinged gate, the motor rotates in a clockwise manner to open thegate. In contrast, when the motor is mounted in the second positioncorresponding to a right-hinged gate, the motor rotates in acounterclockwise manner to open the gate.

[0014] These and other advantages are realized with the describeduniversal power operator. The invention's advantages may be bestunderstood from the following detailed description taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is an exploded top plan view of a universal power operatoraccording to an embodiment of the invention;

[0016]FIG. 2 is a side elevational view of the pivot connection of theuniversal operator shown in FIG. 1;

[0017]FIG. 3 is a top plan view of the assembled universal poweroperator of FIG. 1;

[0018]FIG. 4 is a section view of the motor of the universal poweroperator shown in FIG. 1;

[0019] FIGS. 5-7 are section views of the assembled universal poweroperator of FIG. 1;

[0020]FIG. 8 is a partial section view of the gear assembly and driveshaft of the universal power operator of FIG. 1;

[0021]FIG. 9 is a section view of a mechanical release mechanism of theuniversal power operator of FIG. 1;

[0022]FIG. 10 is a section view of a gear assembly of the universalpower operator of FIG. 1;

[0023]FIG. 11 is a section view of a gear assembly of the universalpower operator of FIG. 1;

[0024]FIG. 12 is a section view of a collar securing the actuator arm tothe universal power operator of FIG. 1;

[0025]FIG. 13 is a section view of a top casing shell, or motor housing,of the universal power operator of FIG. 1;

[0026]FIG. 14 is a section view of a bottom casing shell, or motorsupport housing, of the universal power operator of FIG. 1;

[0027]FIG. 15 is a section view of a motor endbell of the universalpower operator of FIG. 1;

[0028]FIG. 16 is a section view of a top casing shell, or motor housingof FIG. 13;

[0029]FIG. 17 is a section view of a bottom casing shell, or motorsupport housing, of FIG. 14;

[0030]FIG. 18 is a section view of a motor endbell of FIG. 15;

[0031]FIG. 19 is a section view of a securing collar of FIG. 12.

[0032]FIG. 20 is a section view of the assembled universal poweroperator of FIG. 1;

[0033] FIGS. 21-23 are perspective views of the assembled universalpower operator of FIG. 1; and

[0034] FIGS. 24-25 are exploded perspective views of the universal poweroperator of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] FIGS. 1-25 illustrate a universal power operator 1 in accordancewith aspects of the invention. The universal power operator 1 generallycomprises a motor 10 adapted for rotating a driving shaft 30, asillustrated in FIG. 1, wherein rotation of the driving shaft 30 causesthe extension or retraction of an actuator arm 20 relative to thedriving shaft 30 with a predetermined output force. A movable barrier,such as a gate, is pivotably connectable relative to the actuator arm 20and is selectively movable with the predetermined output force thereof.Both the driving shaft 30 and the actuator arm 20 are housed within atube, or hollow housing assembly 40, as illustrated in FIGS. 1 and 7.

[0036] A gear assembly 50 is provided between an output shaft 12 of themotor 10 and the driving member 30 and is operative to shift theactuator arm 20 between retracted and extended positions. The gearassembly 50 preferably includes a connection to the driving shaft 30,two ball bearings 18, and the worm gear 68. The gear assembly 50transmits the rotation power of the motor 10 to the driving member 30.The predetermined output force of the actuator arm 20 is determined bythe gear assembly 50. The gear assembly 50 may be fixed or may be madeselectively adjustable in order to allow configuration and tailoring ofthe operator assembly 1 with a variety of different barrier or gatesizes.

[0037] In the preferred form, the gear assembly 50 includes a worm gear68, as shown in FIGS. 8 and 11, although other such gears adapted fortransmitting rotational forces in perpendicular arrangements couldeasily be used instead. The worm gear 68 used in this embodiment isirreversible, and thus, the motor 10 can drive the worm gear 68 and notvice versa. This is an important security feature because it inhibitsopening of the movable barrier when the barrier is closed.

[0038] Worm gear 68 is adapted to be driven by motor output shaft 12. Inturn, worm gear 68 is operatively connected relative to an end of thedriving shaft 30. Thus, the gear assembly 50 provides for the rotationof the driving shaft 30 via rotation of the motor output shaft 12. Ifdesired, various types of gears could easily be incorporated to providea gearing ratio for adjusting the output force relative to the rotationof the motor output shaft 12.

[0039] As can be seen in FIG. 1, the actuator arm 20, the driving shaft30, and the gear assembly 50 are substantially coaxially aligned witheach other. The coaxial arrangement of the housing assembly 40 and thebilateral accessibility of the gear assembly 50 allow assembly of themotor 10 to either lateral position of the universal power operator 1,as shown in FIG. 3. This interchangeability allows the universal poweroperator 1 to be used with either left-hinged or right-hinged movablebarriers. For instance, the coaxial arrangements provide a universalpower operator 1 that can be used with both left-hinged gates andright-hinged gates.

[0040] The motor 10 may be interchangeably positioned in one of twopositions relative to the housing assembly 40. The motor 10 isinterchangeable because the housing assembly 40 has portions that aregenerally symmetrically arranged on either side of the housing axis andcreating substantially symmetrical spaces in which the motor outputshaft 12 can be received to drive the gear assembly 50. The gearassembly 50 is accessible to the motor output shaft 12 from either side,and the gear assembly 50 drives the actuator arm 20 to open and closethe movable barrier.

[0041] As illustrated in FIGS. 1 and 3, when the universal poweroperator 1 is fully assembled, the gear assembly 50 is disposed within acasing 150. The casing 150 may be formed of a plastic or polymermaterial, and can be shaped to add visual appeal to the universal poweroperator 1, to protect the components from dirt, debris, or liquid,and/or to provide mounting surfaces for the various components thereof.As illustrated in FIG. 1, the casing 150 comprises at least two separateshells 152 and 154 that may be removably joined together to form thecasing 150.

[0042] The casing shells 152 and 154 serve additional purposes. As shownin FIGS. 1 and 13, top casing shell, or motor housing, 152 may beconnected to pivotal connection 2, which in turn may be connected to afixed mount. As shown in FIG. 2, top casing shell 152 may contain anaperture 26 through which a pin may be inserted to attach top casingshell 152 to pivotal connection 2. Alternatively, the top casing shell,or motor housing, 152 and the pivotal connection 2 may be fashioned ofone machined piece.

[0043] As shown in FIGS. 1 and 14, bottom casing shell, or motor supporthousing, 154 has an aperture 158 therethrough for insertion of theoutput shaft 12 of the motor. Bottom casing shell 154 is fashioned toguide and operatively position the output shaft 12 of the motor withrespect to the gear assembly 50. Accordingly, bottom casing shell, ormotor support housing, 154 also serves as a mounting bracket. Casingshells 152 and 154 may be removed by the user to allow the user toreposition the motor 10 for the operation of a left-hinged orright-hinged movable barrier.

[0044] The motor 10 can be assembled on either side of the gear assembly50 without interfering with the performance of the universal poweroperator 1. The accompanying parts fit on either the left or right sideof the gear assembly 50, appearing the same whether installed in eitherorientation. As shown in this embodiment, four bolts 16 are used tosecure the top and bottom casing shells, or motor and motor supporthousings 152 and 154, to the operator 1, thereby creating a strongstable platform for the operator 1, although other types of fastenersmay be used. Because of the general symmetry of the operator design, thetop and bottom casing shells 152 and 154 may be rotated 180 degrees andthe same four mounting bolts 16 used to secure the casing shells 152 and154 to the operator 1. This design results in advantages, such as easyfield changes, relatively few parts, and no additional parts required totransform the operator 1 from one configuration to the other.

[0045] As discussed hereinabove, rotation of the driving shaft 30 causesthe extension or retraction of the actuator arm 20 relative to thedriving shaft 30 with a predetermined output force. When the universalpower operator 1 is pivotably connected at one end to a mount fixedindependently relative to the movable barrier and at another endpivotably connected relative to the movable barrier, the extension orretraction of the actuator arm 20 causes the shifting of the movablebarrier.

[0046] FIGS. 10-11 show a gear assembly 50. In this form, it comprises aconnection to the driving shaft 30, two ball bearings 18, and the wormgear 68, and allows the passage of a mechanical release mechanism 42.The mechanical release mechanism 42 is a standard safety mechanismallowing manual operation of the gate if there is no power (FIG. 9). Thegear assembly 50 design allows the user to attach the driving shaft 30to the operator 1 in the field. The aperture 158 in the bottom casingshell 154 allows the user to operatively connect the driving shaft 30 tothe motor output shaft 12. After the driving shaft 30 is connected, thehousing assembly 40 is inserted into the operator 1 and secured by acollar 44 (FIG. 12). In addition, FIG. 15 shows the motor endbell 160,which supports both the rotor and stator of the motor 10. It can also bemodified and used to support a DC motor.

[0047] In an aspect of the invention, a first pivot connection 2 isprovided at an end of the universal power operator 1. A second pivotconnection 22 is also provided at an end of the actuator arm 20 oppositethe first pivot connection 2, as illustrated in FIGS. 1 and 3. The firstpivot connection 2 is fixable relative to a mount independent of themovable barrier while the second pivot connection 22 is fixable relativeto the movable barrier. These pivot positions may also be reversed. Thepivot connection 22 may be offset from the longitudinal axis of the arm20, such as by forming a bend or elbow in the arm 20, to provide amechanical advantage or to provide for a variety of differentinstallation configurations for the universal power operator 1.

[0048] The driving shaft 30 may comprise a: shaft 32 having externalthreads 34 thereon, as illustrated in FIGS. 7 and 8. A threaded memberor nut 100 is provided on the opposite end of the actuator arm 20 fromthe pivot connection 22. The external threads 34 of the driving shaft 30cooperate with internal threads formed on the nut 100 to extend orretract the actuator arm 20 relative to the driving shaft 30.

[0049] The actuator arm 20 may be shiftably received in the housingassembly 40 along the housing axis, such that it may be axiallyretracted into the housing 40 and axially extended out from the housing40. In its retracted state the actuator arm 20 is substantially receivedwithin the housing 40, and the nut 100 is in threaded engagement withthe shaft 30 and located proximate the motor 10, as illustrated in FIG.7. As the driving shaft 30 rotates, the external threads 34 thereon, incombination with the pivot connection 22 being fixed relative to thedriving shaft 30, cause the outward extension of the arm 20 relative tothe housing assembly 40 to an extended position. Different lengths ofarms 20 and housing assemblies 40 may be used to vary the amount ofextension of the arm 20.

[0050] As illustrated in FIG. 2, the pivot connections 2 and 22 may eachcomprise a flattened region 24 with an aperture therethrough 26. Abushing or other friction reducing surface, such as a bronze or plasticbushing, may be provided for insertion through the aperture and around apin. An aperture 26 may be adapted to receive the pin or other suitablemember for pivotably connecting the casing shell 152 to a fixed mount.An aperture 26 may also be used for pivotably connecting actuator arm 20to the movable barrier, such as with a yoke mounted relative to thebarrier. Forming pivot connection 22 with a flattened region 24minimizes the number of parts required for the actuator arm 20, such asif a separate pivot connection were attached to the end of the arm 20.Furthermore, the pivot connection 22 provides for simplified manufactureof the actuator arm 20. For example, the pivot connection 22 may beformed by flattening, crimping, or stamping a cylindrical tube to createthe flattened region 24. The aperture 26 may be provided in theflattened region 24 after the flattening thereof. The aperture 26 mayalso be provided in the cylindrical tube prior to flattening thereof.

[0051] The term barrier, as used herein, includes gates and othermovable barriers. The barrier may include a single hinged gate, or dualhinged gates, each having an operator assembly 1 for shifting thereof.Other types of gate configurations and barriers are also contemplated bythe invention, and the universal power operator 1 of the invention maybe used therewith.

[0052] As stated above, the universal power operator 1 includes amodular motor 10 that can be mounted in either of two positions. Thepresent invention further includes a circuit control system foroperating the motor 10 depending on how the motor 10 is mounted. Eachuniversal power operator 1 has circuit connections for a left movablebarrier and a right movable barrier, and each circuit connection has twophase wires. When one phase wire is energized, the motor 10 operates inone direction, i.e., in a clockwise direction. When the other phase wireis energized, however, the motor 10 runs in the opposite direction,i.e., in a counterclockwise direction. For each mounting position, thephase wires are reversed, i.e., the logic is reversed, and accordingly,the rotation of the motor 10 is reversed. For example, when the motor 10is mounted in one position corresponding to a left-hinged gate, themotor 10 may rotate in a clockwise manner to open the gate. In contrast,when the motor 10 is mounted in the second position corresponding to aright-hinged gate, the motor 10 may rotate in a counterclockwise mannerto open the gate. In the preferred embodiment, the operator 1 usesstandard circuit connections.

[0053] While there have been illustrated and described particularembodiments of the present invention, it will be appreciated thatnumerous changes and modifications will occur to those skilled in theart, and it is intended in the appended claims to cover all thosechanges and modifications which fall within the true spirit and scope ofthe present invention.

What is claimed is:
 1. A universal power operator for shifting aleft-hinged or right-hinged operating movable barrier between open andclosed positions thereof, the power operator comprising: an actuator armfor being connected to the movable barrier to push and pull the movablebarrier between the open and closed positions thereof, a housingassembly in which the arm is shiftably received along a housing axis tobe axially retracted into the housing and axially extended out from thehousing for shifting of the movable barrier; a gear assembly operable toshift the arm between the retracted and extended positions thereof, amodular drive motor including an output shaft for driving the gearassembly; and portions of the housing assembly generally symmetricallyarranged on either side of the housing axis to form symmetrical spacesin which the output shaft of the modular drive motor can be received fordriving of the gear assembly to allow the motor to be repositioned inone of two positions relative to the housing assembly based on whetherthe movable barrier is a left-hinged or right-hinged operating movablebarrier.
 2. The universal power operator of claim 1, wherein the gearassembly comprises an irreversible worm gear for inhibiting opening ofthe movable barrier when the barrier is closed.
 3. The universal poweroperator of claim 1, further comprising a circuit control system fordriving the motor in one direction to open the movable barrier when itis a left-hinged operating movable barrier and for driving the motor inthe opposite direction to open the movable barrier when it is aright-hinged movable barrier.
 4. The universal power operator of claim1, further comprising a casing for supporting and operatively connectingthe motor to the gear assembly.
 5. The universal power operator of claim4, wherein the casing is further comprised of two shells, one of whichcontains an aperture allowing the motor to be operatively connected tothe gear assembly.
 6. The universal power operator of claim 5, whereinthe two shells can be interchangeably connected to either lateral sideof the housing axis allowing the motor to be interchangeably mounted tothe operator on either side of the housing axis.